Table of Contents
FOREWORD .............2
APQP FUNDAMENTALS ...........5
APQP Process Flow Map................6
Fundamentals of the APQP Process .................7
APQP REPORTING PROCESS .................10
APQP Status Reporting Process Flow Chart...11
APQP Status Report ...12
APQP Status Report Form.............13
Filling Out the Status Report Form.14
Quality of Event Checklists ............15
Risk Assessment.........15
APQP TIMING.........17
Ford / Supplier Systems V Model 18
APQP Generic Program Timing Gantt Chart ...19
APQP ELEMENTS..21
Sourcing Decision .......22
Customer Input Requirements .......23
Craftsmanship .............24
Design Failure Mode and Effects Analysis (DFMEA) ........25
Design / Manufacturing Reviews....27
Design Verification Plan & Report (DVP&R)....28
Sub-Contractor APQP Status.........29
Facilities / Tools / Gauges.............30
Prototype Build Control Plan..........32
Prototype Builds ..........33
Drawings & Specifications.............34
Team Feasibility Commitment........36
Manufacturing Process Flow..........37
Process Failure Mode and Effects Analysis (PFMEA).......38
Measurement System Evaluation ..40
Pre-Launch Control Plan...............41
Operator Process Instructions.......42
Packaging Specifications ...............43
Production Trial Run ...44
Production Control Plan .................46
Preliminary Process Capability ......47
Production Validation Testing ........48
Part Submission Warrant (PSW)....50
APPENDIX SECTION ...............52
APPENDIX A: APQP ROLES & RESPONSIBILITIES 53
VO – PD APQP Lead/Support Responsibilities – Relationship Table .54
Powertrain Roles and Responsibilities Matrix…..55
Powertrain Program Review Process ..............56
STA Roles & Responsibilities........57
EXTERNAL SUPPLIERS..........67
APPENDIX B: RELATED FORMS ................69
APPENDIX C: GLOSSARY OF TERMS ..........72
APPENDIX D: REFERENCES AND WEBSITES.79
APPENDIX E: CHANGE INDEX ……………..84